Part-scale finite element simulation and investigation of machining allowances for laser-based powder bed fusion components
Rizwan Ullah et al.
What the paper says
Laser-based powder bed fusion (PBF-LB) components must meet strict geometric tolerances, requiring effective post-processing. The absence of ISO standards for finishing PBF-LB parts necessitates investigation of finishing processes and cumulative geometric deviations to achieve dimensional accuracy. This study validates the use of a general-purpose FEM solver (Abaqus) to predict geometric deviations during PBF-LB and subsequent support removal of an engineering-representative component. A representative PBF-LB component was manufactured, followed by support removal and 5-axis milling as finishing process. Geometric deviations were measured using CMM, and a T6 heat treatment was applied to assess stress relief and geometric distortions. Non-heat-treated components showed deviations of 0.333 mm from residual stresses and 0.600 mm from machining setup misalignment, causing non-uniform material removal. Heat-treated components exhibited reduced distortions of 0.266 mm and uniform material removal. Based on cumulative deflections, a machining allowance of at least 0.7 mm is recommended for curved components. Surface roughness improved after milling, with reductions of at least 23% on curved profiles. The finite element model successfully predicted residual-stress-induced distortions, with simulations closely matching experiments (26% error), demonstrating reliability and adaptability for predicting PBF-LB distortions and machining allowances.
Evidence weight
Balanced mode · F 0.40 / M 0.15 / V 0.05 / R 0.40
| F · citation impact | 0.50 × 0.4 = 0.20 |
| M · momentum | 0.50 × 0.15 = 0.07 |
| V · venue signal | 0.50 × 0.05 = 0.03 |
| R · text relevance † | 0.50 × 0.4 = 0.20 |
† Text relevance is estimated at 0.50 on the detail page — for your query’s actual relevance score, open this paper from a search result.